Reliance electric GV3000 Instructions Manual
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Reliance electric GV3000 Instructions Manual

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GV3000/SE AC Drive
Hardware Reference, Installation,
and Troubleshooting
Version 6.06
Instruction Manual
D2-3360-5

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  • Page 1 GV3000/SE AC Drive Hardware Reference, Installation, and Troubleshooting Version 6.06 Instruction Manual D2-3360-5...
  • Page 2 DeviceNet is a trademark of Open DeviceNet Vendor Association. ControlNet is a trademark of ControlNet International Ltd is a trademark of International. PROFIBUS PROFIBUS GV3000, AutoMax, and Reliance are trademarks of Rockwell Automation. ©2000 Rockwell International Corporation...

  • Page 3: Table Of Contents

    About the Drive Identifying the Drive by Model Number ............2-1 NEMA Enclosures ................... 2-3 1-25 HP GV3000/SE Drive Component Locations .......... 2-4 25-60 HP GV3000/SE Drive Component Locations ........2-7 60-100 HP GV3000/SE Drive Component Locations ........2-8 100-150 HP GV3000/SE Drive Component Locations ........2-9 200-400 HP GV3000/SE Drive Component Locations ........
  • Page 4 Technical Specifications................... A-1 Appendix B Compliance with Machinery Safety Standard EN 60204-1:1992 ......B-1 Appendix C Compliance with Electromagnetic Compatibility Standards ........C-1 Appendix D 200-400 HP GV3000/SE System Wiring Diagrams ..........D-1 Index ...........................Index-1 GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 5: List Of Figures

    List of Figures Figure 2.1 – Identifying the Drive Model Number ............. 2-1 Figure 2.2 – 1-5 HP Drive Component Locations ............. 2-4 Figure 2.3 – 7.5-10 HP Drive Component Locations ..........2-5 Figure 2.4 – 15-25 HP Drive Component Locations ..........2-6 Figure 2.5 –...
  • Page 6 GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 7: List Of Tables

    List of Tables Table 2.1 – Power and NEMA Enclosure Ratings ............ 2-2 Table 2.2 – Standard Kits and Options ..............2-20 Table 3.1 – Environmental Conditions..............3-2 Table 3.2 – Drive Dimensions and Weights.............. 3-2 Table 3.3 – Recommended Power Wire Sizes for 1-10 HP Drives ......3-5 Table 3.4 –...
  • Page 8 GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 9: Chapter 1 Introduction

    HAPTER Introduction This instruction manual describes the GV3000/SE drive hardware. It does not cover the GV3000/SE drive software. For software information, refer to the GV3000/SE AC General Purpose (V/Hz) and Vector Duty Drive Software Start-Up and Reference Manual (D2-3359). This manual is intended for qualified electrical personnel. It is organized according to a logical progression of steps to be followed to install and troubleshoot the drive.
  • Page 10 GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 11: Chapter 2 About The Drive

    2.1 Identifying the Drive by Model Number Each GV3000/SE AC drive can be identified by its model number. See figure 2.1. This number appears on the shipping label and on the drive’s nameplate. The drive’s model number includes the Power Module and the regulator.

  • Page 12: Table 2.1 - Power And Nema Enclosure Ratings

    With V/Hz regulation, 110% continuous output current capability. With vector regulation, 150% output current capability for one minute. Input Voltage: 380-460 VAC (+/-10%) With optional input disconnect factory installed 110% overload only at 4KHz in V/Hz and vector modes. GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 13: Nema Enclosures

    2.2 NEMA Enclosures Each of the GV3000/SE drives have one of following NEMA ratings: • NEMA 1: Vented. Contains a communication access door that allows access to the communication port without removing the cover. Intended for general-purpose indoor applications. •...

  • Page 14: Hp Gv3000/Se Drive Component Locations

    2.3 1-25 HP GV3000/SE Drive Component Locations The 1-25 HP GV3000/SE drives have the following main components. The numbered items listed below correspond to the numbers used in figures 2.2 to 2.4. Replacement parts are listed in chapter 9. Fan Assembly...

  • Page 15: Figure 2.3 - 7.5-10 Hp Drive Component Locations

    7V41XX 7V42XX 10V41XX 10V42XX Figure 2.3 – 7.5-10 HP Drive Component Locations About the Drive...

  • Page 16: Figure 2.4 - 15-25 Hp Drive Component Locations

    15V41XX 25G41XX 15V42XX 25G42XX 20V41XX 20V42XX Figure 2.4 – 15-25 HP Drive Component Locations GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 17: Hp Gv3000/Se Drive Component Locations

    2.4 25-60 HP GV3000/SE Drive Component Locations The 25-60 HP drives have the following main components. The numbered items listed below correspond to the numbers used in figure 2.5. Replacement parts are listed in chapter 9. Power Supply PCB Membrane Switch (Keypad/Bracket)

  • Page 18: Hp Gv3000/Se Drive Component Locations

    2.5 60-100 HP GV3000/SE Drive Component Locations The 60-100 HP drives have the following main components. The numbered items listed below correspond to the numbers used in figure 2.6. Replacement parts are listed in chapter 9. Regulator Printed Circuit Board (PCB)

  • Page 19: Hp Gv3000/Se Drive Component Locations

    2.6 100-150 HP GV3000/SE Drive Component Locations The 100-150 HP drive has the following main components. The numbered items listed below correspond to the numbers used in figure 2.7. Replacement parts are listed in chapter 9. Regulator Printed Circuit Board (PCB)

  • Page 20: Hp Gv3000/Se Drive Component Locations

    2.7 200-400 HP GV3000/SE Drive Component Locations The 200-400 HP drive has the following main components. The numbered items listed below correspond to the numbers used in figure 2.8. Replacement parts are listed in chapter 9. Terminal Block Assembly Blower Assembly...

  • Page 21: Regulator Board Description

    The 1-60 HP Regulator board provides a signal for use by an optional snubber resistor braking kit for 1-10 HP drives. The signal is available through the terminal strip. Three Regulator boards are used on the GV3000/SE drives: • 1-60 HP Regulator boards are used with 1-60 HP drives (M/N 1V4XXX to 60G4XXX) •...

  • Page 22: Figure 2.9 - 1-60 Hp Regulator Board Component Locations

    J9 - Keypad/Display Connector J4 - Analog Input Jumper J17 - Analog Output Jumper J5 - Power Module Feedback Cable J7 - OIM (Optional) Connector Figure 2.9 – 1-60 HP Regulator Board Component Locations 2-12 GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 23: Figure 2.10 - 60-150 Hp Regulator Board Component Locations

    60-Pin Ribbon Cable USER DISPLAY USER I/O TERMINAL STRIP J3 - Option Board Connector J9 - Keypad/Display Connector J4 - Analog Input Jumper J16 - Power Module Feedback Cable J7 - OIM (Optional) Connector J17 - Analog Output Jumper J8 - RS232C Port Figure 2.10 –...

  • Page 24: Figure 2.11 - 200-400 Hp Regulator Board Component Locations

    J4 - Analog Input Jumper J16 - Power Module Feedback Cable J7 - OIM (Optional) Connector J17 - Analog Output Jumper J8 - RS232C Port Figure 2.11 – 200-400 HP Regulator Board Component Locations 2-14 GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 25: Jumper Locations And Settings

    Be sure to verify that parameters P.009, P.010, and P.011 are correct before starting the drive. Refer to the GV3000/SE Software Start-Up and Reference manual for more information.

  • Page 26: Setting The Analog Output Jumper (J17)

    Input Gain (P.010), and Terminal Strip Analog Input Configure (P.011) are correctly set. Note that the jumper settings must match the software settings otherwise the reference value may differ from what is expected. Refer to the GV3000/SE Software Start-Up and Reference manual for more information. Voltage Input Option...

  • Page 27: Wiring The Terminal Strip

    Step 3. Verify that the DC bus voltage is zero by following the procedure in section 9.3. Step 4. Locate jumper J17 on the Regulator board. Refer to figures 2.9, 2.10, and 2.11. Step 5. Locate pin 1 on jumper J17. Move the jumper to the desired setting as shown in figure 2.13.

  • Page 28: Communication Port

    2.8.3 RS-232 Communication Port The Regulator board contains a 9-pin D-shell RS-232 communication port (J8). This port provides RS-232 communication between the GV3000/SE drive and a personal computer running the Control and Configuration (CS3000) software. See figures 2.9, 2.10, and 2.11. Refer to instruction manual D2-3348 for more information about the CS3000 software.

  • Page 29: Option Board Connector

    DeviceNet Option board, the RMI board, the AutoMax Network Option board, or similar boards to the GV3000/SE drive. See figures 2.9, 2.10, and 2.11. The option board is mounted below the Regulator board inside the drive. Refer to the appropriate board instruction manual for more information.

  • Page 30: Optional Equipment

    2.9 Optional Equipment Table 2.2 lists standard GV3000/SE kits and options. Table 2.2 – Standard Kits and Options Description Model Number Instruction Manual 2SR20400 D2-3291 2SR20600 2SR21200 Snubber Resistor Braking Kits 2SR21800 (NEMA 1 Enclosed) 2SR40400 2SR40600 2SR41200 2SR41800 2ST20019...
  • Page 31 Table 2.2 – Standard Kits and Options (Continued) Description Model Number Instruction Manual DeviceNet Network Option Board 2DV3000 MAN0096-03 Operator Interface Module (OIM) 2RK3000 D2-3342 CS3000 Control and Configuration 2CS3000 D2-3348 Software CS3000 RS-232 Computer Cable 2CA3000 D2-3348 115 VAC Interface Option Board 2LB3000 D2-3376 ...
  • Page 32 2-22 GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 33: Chapter 3 Planning Before Installing

    3.1 General Requirements for the Installation Site It is important to properly plan before installing a GV3000/SE drive to ensure that the drive’s environment and operating conditions are satisfactory. Note that no devices are to be mounted behind the drive.

  • Page 34: Determining Total Area Required Based On Drive Dimensions

    57.36" 12.99" 55.66" 13.97" 211 lbs 600 mm 2200 mm 200V4160 250V4160 382.5 kg 600 mm 300V4160 350V4160 23.6" 86.6" 850 lbs 23.6" 400V4160 Dimension E is 660 mm (26.0") with optional disconnect. GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 35: Figure 3.1 - Drive Dimensions

    L R U 1-60 HP C R L U L R U 60-150 HP 200-400HP Figure 3.1 – Drive Dimensions Planning Before Installing...

  • Page 36: Verifying The Site Provides For Recommended Air Flow Clearances

    Be sure there is adequate clearance for air circulation around the drive. For best air movement, do not mount GV3000/SE drives directly above each other. Note that no devices are to be mounted behind the drive. This area must be kept clear of all control and power wiring.

  • Page 37: Verifying Power Module Input Ratings Match Supplied Power

    3.1.4 Verifying Power Module Input Ratings Match Supplied Power It is important to verify that plant power will meet the input power requirements of the drive’s Power Module circuitry. Refer to table 2.1 for input power rating specifications. Be sure input power to the drive corresponds to the drive nameplate voltage and frequency.

  • Page 38: Table 3.4 - Recommended Power Wire Sizes For 15-25 Hp Drives

    AC Input Power R/L1, S/L2, T/L3 350 MCM (2X), 177 mm Output Power U/T1, V/T2, W/T3 DC Bus Connections DC-, DC+ Ground Wires must be lugged. Lugs must be Burndy YA31-2N or equivalent. GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 39: Recommended Control And Signal Wire Sizes

    To reduce line disturbances and noise, motor lead length should not exceed 76 meters (250 feet) for any non-Reliance Electric motor or any non-inverter duty motor. When total lead length exceeds 76 meters (250 feet), nuisance trips can occur caused by capacitive current flow to ground.

  • Page 40: Table 3.10 - Recommended Motor Lead Lengths For Reliance Inverter Duty Motors

    RL-50003 RL-05503 RL-50003 Standard reactors can be used on GV3000/SE drives with carrier frequency settings up to 8 kHz. All reactors listed are UL-recognized (UL-506 File #E53094) and CSA certified (CSA File #LR29753). GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 41: Recommended Serial Communication Cable Lengths

    3.2.5 Verifying Power Module Output Current Rating Is Greater Than Motor Full Load Amps Verify that the GV3000/SE output current rating is greater than the motor’s full load current (amps). Table 2.1 lists the output current values. Planning Before Installing...

  • Page 42: Table 3.12 - Ac Input Line Fuse Selection Values

    *Recommended fuse type: UL Class J, 600 V, time delay, or equivalent. **The drive contains internal fusing sized to protect the drive. Install fuses to protect the input wiring in accordance with local codes. 3-10 GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 43: Mounting The Drive

    Use grommets, when hubs are not provided, to guard against wire chafing. Figures 4.1 through 4.7 show the wire routing, grounding terminal, and power terminal strips of the GV3000/SE drives. ATTENTION: Do not route signal and control wiring with power wiring in the same conduit.

  • Page 44: Replacing Conduit Plugs

    When adding more than one grounding conductor wire to a single chassis ground, twist the conductors together. Step 4. Reattach the drive’s cover. On 200-400 HP drives, close the outer cabinet door. GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 45: Figure 4.1 - Wire Routing Locations For 1-5 Hp Drives

    AUTO Forward RUNNING Reverse REMOTE VOLTS AMPS PROGRAM AUTO FORWARD TORQUE REVERSE ENTER Password PROGRAM STOP START RESET REGULATOR TERMINAL STRIP POWER TERMINAL STRIP GROUND TERMINAL SIGNAL CONTROL SIGNAL CONTROL INPUT POWER (TERMINAL STRIP) -OR- AND MOTOR LEADS SNUBBER RESISTOR BRAKING USER WIRE ROUTING COVER...

  • Page 46: Figure 4.2 - Wire Routing Locations For 7.5-10 Hp Drives

    BRAKING USER WIRE ROUTING COVER BASE (4) 1/2" NPT CONDUIT HUBS (NEMA 4X/12) -OR- (4) .875 [22.2mm] DIA Bottom View HOLES (NEMA 1) Figure 4.2 – Wire Routing Locations for 7.5-10 HP Drives GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 47: Figure 4.3 - Wire Routing Locations For 15-25 Hp Drives

    AUTO Forward RUNNING Reverse VOLTS REMOTE AMPS PROGRAM AUTO FORWARD TORQUE REVERSE ENTER Password PROGRAM REGULATOR TERMINAL STRIP STOP START RESET OWER STRIP TERMINALS U/T1 V/T2 W/T3 R/L1 S/L2 T/L3 GROUND TERMINALS MOTOR LEADS SIGNAL CONTROL INPUT POWER -OR- (TERMINAL STRIP) -OR- INPUT POWER SNUBBER RESISTOR...

  • Page 48: Figure 4.4 - Wire Routing Locations For 25-60 Hp Drives

    1.75” [44.5 mm] DIA HOLES 1.125” [28.6 mm] DIA HOLES (2 TOP, 3 BOTTOM) (1 TOP, 2 BOTTOM) BASE BASE MOUNTING BRACKET BOTTOM VIEW Figure 4.4 – Wire Routing Locations for 25-60 HP Drives GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 49: Figure 4.5 - Wire Routing Locations For 60-100 Hp Drive

    DC INPUT TERMINALS 1-3/4" DIA AND GROUND TYPICAL MOTOR LEADS SIGNALS VIEW FROM BOTTOM (PE1) IL1 IL2 IL3 AC INPUT TERMINALS AND GROUND AC OUTPUT TERMINALS AND GROUND Figure 4.5 – Wire Routing Locations for 60-100 HP Drive Mounting the Drive, Grounding, and Finding Wire Routing Locations...

  • Page 50: Figure 4.6 - Wire Routing Locations For 100-150 Hp Drives

    AND GROUND 1-1/2" DIA GROUND TYPICAL INPUTS VIEW FROM BOTTOM AC OUTPUT TERMINALS 1-1/2" DIA SIGNALS GROUND 7/8" DIA OUTPUT TYPICAL TERMINALS TYPICAL Figure 4.6 – Wire Routing Locations for 100-150 HP Drives GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 51: Figure 4.7 - Wire Routing Locations For 200-400 Hp Drives

    GROUND, A-C INPUT AND A-C OUTPUT TERMINALS SIGNALS (VIA WIRING TRAY) VIEW FROM TOP (with Cover Removed) POWER CONNECTIONS PULL SHIELD TABS IN AND ROTATE SHIELD OUT CONNECT USING 350MCM TWO HOLE TERMINAL LUGS TORQUE TO 325IN-LBS VOLTMETER TEST POINTS DANGER DANGER WIRING HARNESS 807300-138R...
  • Page 52 4-10 GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 53: Chapter 5 Installing Input Power Wiring

    DC bus voltage. Failure to observe these precautions could result in damage to, or destruction of, the equipment The GV3000/SE AC line distribution system capacity is 1000 KVA, three-phase with 30,000 amps symmetrical fault current capacity with a line impedance of less than 5%.

  • Page 54: Installing Fuses For Branch Circuit Protection

    Refer to section 5.1 for additional information. Note that 200-400 HP drives may be supplied with an optional AC disconnect. GV3000/SE AC Drive Hardware Reference, Version 6.06...
  • Page 55 3-Phase AC 3-Phase AC Input Voltage 460 V Input Voltage 460 V Manual Disconnect User- Supplied Fuse Fuse User- Supplied GND (PE) Manual Disconnect (Optional) Fuse (PE) GV 3000/SE GV 3000/SE Power Power Module Module Motor Overload Motor Overload User- User- Relay (Optional if Relay (Optional if...

  • Page 56: Figure 5.2 - Typical Dc Bus Electrical Connections

    (Optional if Electronic User-Supplied Overload is Used) Note that the following GV3000/SE drives are not to be used on a common DC bus: M/N 125R4160, 200V4160, 250V4160, 300V4160, and 400V4160. Figure 5.2 – Typical DC Bus Electrical Connections GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 57: Installing Power Wiring From The Ac Input Line To The Drive's Power Terminals

    5.4 Installing Power Wiring from the AC Input Line to the Drive’s Power Terminals Use the following steps to connect AC input power to the drive: Step 1. Wire the AC input power leads by routing them according to drive type. Refer to figures 4.1 through 4.7.

  • Page 58: Installing Power Wiring From An External Dc Bus To The Drive's Internal Dc Bus Terminals

    Step 1. Wire the DC input power leads by routing them according to drive type. Refer to figures 4.1 through 4.7. Tables 3.3 through 3.8 contain the recommended power wiring sizes. Note that the following GV3000/SE drives are not to be used on a common DC bus: M/N 125R4160, 200V4160, 250V4160, 300V4160, 350V4160, and 400V4160.

  • Page 59: Chapter 6 Installing Output Power Wiring

    6.1 Installing Output Contactors (Optional) Output contactors provide a positive means of disconnecting the motor from the drive. If the application requires the use of output contactors, contact Reliance Electric for assistance. 6.2 Installing Mechanical Motor Overload Protection...
  • Page 60 On 200-400 HP drives, connect the motor leads to terminals U/T1, V/T2, and W/T3. Step 3. Tighten the three-phase AC output power terminals to the proper torque according to drive type as shown in table 5.2. GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 61: Table 7.1 - Rs-232 Connections (Terminals 1-3)

    Note that when the Control Source parameter (P.000) is set to remote (rE), the drive will be controlled by the signals connected to the terminal strip. Refer to the GV3000/SE Software Start-Up and Reference manual for more information on how parameter P.000 is used to specify where the drive is controlled from.

  • Page 62: Table 7.3 - Analog Output Connections (Terminals 10 And 11)

    +/-20 mA, as determined by the setting of jumper J4 on the Regulator board. The analog reference can be adjusted using parameters P.009, P.010, and P.011. Refer to Appendix G in the GV3000/SE Software Start-Up and Reference manual for more information about the analog input.

  • Page 63: Table 7.6 - Snubber Resistor Braking Connections (Terminals 26 And 27)

    Signal N.C Relay Contact N.C. Relay Common N.O. Relay Contact N.O. Relay Common Notes: Relay contact closure is programmable through parameter P.013. Refer to the GV3000/SE Software Start-Up and Reference manual for more information. Wiring the Regulator Board Terminal Strip...

  • Page 64: Figure 7.1 - Two-Wire Start/Stop Sample Control Wiring

    Sense Start Enable) = ON and P.026 (Function Loss Response) = 1. *FOR 15-60 HP DRIVES, USE 16A INSTEAD OF 16 AND 20A INSTEAD OF 20. ALSO SEE FIGURE 2.14. Figure 7.1 – Two-Wire Start/Stop Sample Control Wiring GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 65: Chapter 7 Wiring The Regulator Board Terminal Strip

    Remote 4-20 mA Speed/Torque Reference Important: A maintained function loss switch should be used if P.054 (Level Sense Start Enable) = ON and P.026 (Function Loss Response) = 1. *FOR 15-60 HP DRIVES, USE 16A INSTEAD OF 16 AND 20A INSTEAD OF 20. ALSO SEE FIGURE 2.14. Figure 7.2 –...

  • Page 66: Stopping The Drive

    Failure to observe this precaution could result in bodily injury. Depending upon the requirements of the application, the GV3000/SE drive can be programmed to provide either a coast-to-rest or a ramp-to-rest operational stop without physical separation of the power source from the motor.

  • Page 67: Wiring The Encoder Feedback Device (Fvc Regulation Only)

    7.2 Wiring the Encoder Feedback Device (FVC Regulation Only) If the GV3000/SE drive is programmed to provide FVC regulation, an encoder must be installed. Drives using V/Hz or SVC regulation do not require the use of an encoder feedback device. The encoder connects to terminals 4 through 9 of the Regulator board terminal strip as shown in table 7.8.

  • Page 68: Figure 7.3 - Encoder Wiring Connections

    Phase A Not Terminal 4 Pin 1 0 VDC Terminal 9 Pin 6 +15 VDC Terminal 7 Pin 2 Phase B Terminal 8 Pin 7 Phase B Not Figure 7.3 – Encoder Wiring Connections GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 69: Wiring The Signal And Control I/O

    7.3 Wiring the Signal and Control I/O Wire the drive’s signal and control I/O to the terminal strip as shown in table 7.8. Table 7.9 – Wiring Signal and Control I/O to the Terminal Strip Terminal Number Description Parameters/Wiring Connections Wiring RS-232 Signals RS-232 Transmit Note that RS-232 communication between the drive and a...
  • Page 70 9 and 11 are internally connected. Terminal Strip Load (Meter or Analog Input) Connection to the negative side of the power supply is only required when an external 15V power supply is used. 7-10 GV3000/SE AC Drive Hardware Reference, Version 6.06...
  • Page 71 Jumper J4 must also be set. See figure 2.12. Isolated Speed/Torque Reference Common (Voltage/Current) Refer to Appendix G in the GV3000/SE Software Start-Up and Reference manual (D2-3359) for more information about the analog input. 7-11 Wiring the Regulator Board Terminal Strip...
  • Page 72 P.023: MOP Accel/Decel Time • P.024: MOP Reset Configuration • P.031 to P.038: Preset Speeds 1-8 Refer to the GV3000/SE Software Start-Up and Reference manual for additional information. Terminal 17 On = Local Control Diagram shows factory setting. 7-12 GV3000/SE AC Drive Hardware Reference, Version 6.06...
  • Page 73 P.023: MOP Accel/Decel Time • P.024: MOP Reset Configuration • P.031 to P.038: Preset Speeds 1-8 Refer to the GV3000/SE Software Start-Up and Reference manual for additional information. Terminal 18 On = Ramp 2 Diagram shows factory setting. 7-13 Wiring the Regulator Board Terminal Strip...
  • Page 74 P.023: MOP Accel/Decel Time • P.024: MOP Reset Configuration • P.031 to P.038: Preset Speeds 1-8 Refer to the GV3000/SE Software Start-Up and Reference manual for additional information. If P.027 = 1 Forward Direction Only Terminal 19 On = Reverse Direction Diagram shows factory setting.
  • Page 75 Table 7.8 - Wiring Signal and Control I/O to the Terminal Strip (Continued) Terminal Number Description Parameters/Wiring Connections Wiring a Function Loss Input Digital Input 5 The following parameter must be set: (Function Loss) • P.026: Function Loss Response A signal must be present at terminal 20 for the drive to be able to start.
  • Page 76 (for example, the M/N 2DB4010 series). +24 VDC Isolated Common Note that terminals 26 and 27 are not to be used with Snubber Resistor Braking Kits M/N 2SR40400, 2SR40600, 2SR41200, and 2SR41800. 7-16 GV3000/SE AC Drive Hardware Reference, Version 6.06...
  • Page 77 Note that depending on the setting of parameter P.013, the relay coil will energize (the normally-open contact will close Normally-Open Contact and the normally-closed contact will open). Refer to the Common (Form A) GV3000/SE Software Start-Up and Reference manual for more information. N.O. N.C. Com.
  • Page 78 7-18 GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 79: Chapter 8 Completing The Installation

    HAPTER Completing the Installation This chapter provides instructions on how to perform a final check of the installation before power is applied to the drive. ATTENTION: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should start and adjust it.

  • Page 80: Installing The Cover For Nema 4X/12 Drives

    Step 1. Turn the drive’s input power disconnect to the On position. Step 2. Apply power to the drive. Step 3. Follow the start-up procedure in the GV3000/SE Software Start-Up and Reference manual. GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 81: Chapter 9 Troubleshooting The Drive

    If a fault occurs, the drive will coast-to-rest stop and a 2- or 3-digit fault code will flash on the display. Refer to the GV3000/SE Software Start-Up and Reference manual for more information on drive alarms and faults. 9.3 Verifying That DC Bus Capacitors Are Discharged ATTENTION: DC bus capacitors retain hazardous voltages after input power has been disconnected.
  • Page 82 Appendix D. Step 5. Once the drive has been serviced, reattach the drive’s cover. On 200-400 HP drives, close the inner and outer cabinet doors. Step 6. Reapply input power. GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 83: Figure 9.1 - Dc Bus Voltage Terminals (1-25 Hp Drives)

    1-10 HP V/T2 W/T3 R/L1 T/L3 10 COM U/T1 S/L2 AC Power Motor Leads DC Bus Input Leads Volts 15-25 HP U/T1 V/T2 W/T3 S/L2 R/L1 T/L3 Motor Leads AC Power DC Bus Volts Input Leads Figure 9.1 – DC Bus Voltage Terminals (1-25 HP Drives) Troubleshooting the Drive...

  • Page 84: Figure 9.2 - Dc Bus Voltage Terminals (25-60 Hp Drives)

    DC Bus AC Power Volts Input Leads R/L1 S/L2 T/L3 Figure 9.2 – DC Bus Voltage Terminals (25-60 HP Drives) GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 85: Figure 9.3 - Dc Bus Voltage Terminals (60-100 Hp Drives)

    DC Bus Measuring Points IL1 IL2 IL3 Figure 9.3 – DC Bus Voltage Terminals (60-100 HP Drives) Troubleshooting the Drive...

  • Page 86: Figure 9.4 - Dc Bus Voltage Terminals (100-150 Hp Drives)

    Regulator Panel (DC Bus Measuring Points Behind Regulator Panel on the Power Module Interface Board) Power Module Inteface Board Fuses DC Bus Measuring Points Figure 9.4 – DC Bus Voltage Terminals (100-150 HP Drives) GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 87: Figure 9.5 - Dc Bus Voltage Terminals (200-400 Hp Drives)

    POWER CONNECTIONS Initial DC Bus Measuring Points (Inner Door Closed) PULL SHIELD TABS IN AND ROTATE SHIELD OUT CONNECT USING 350MCM TWO HOLE TERMINAL LUGS TORQUE TO 325IN-LBS (When the bus voltage is 50 VDC or less, the inner door may be opened and the voltage measured on the DC bus bars as shown below.) GND DB DC- DANGER...

  • Page 88: Checking Out The Drive With Input Power Off

    Modules (IPM) may be replaced in 60–150 HP drives. Step 8. Reconnect the motor to the drive. Step 9. Reattach the drive’s cover. On 200–400 HP drives, close the inner and outer cabinet doors. Step 10. Reapply input power. GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 89: Table 9.1 - Resistance Checks

    Table 9.1 – Resistance Checks 1–60 HP Drives Input Meter Diode Connection Component is OK if resistance (R) is: Component is defective if: R/L1 50K < R < 10 Megohms Continuity (short circuit) or open when the meter is S/L2 connected with reversed T/L3 polarity...
  • Page 90 Connection Component is OK if resistance (R) is: Component is defective if: 0.3 kohm < R < 8 kohm Continuity (short circuit) or open when the meter is connected with reversed polarity 9-10 GV3000/SE AC Drive Hardware Reference, Version 6.06...
  • Page 91 Table 9.1 - Resistance Checks (Continued) 200–400 HP Drives (with the motor connected) Meter IGBT Connection Component is OK if resistance (R) is: Component is defective if: U/T3 10 < R < 1 Megohm Continuity (short circuit) or IGBTs open when the meter is U/T3 tested in connected with reversed...

  • Page 92: Replacement Parts

    9.5 Replacement Parts Tables 9.2 to 9.8 list the replacement parts that are available from Reliance Electric. See figures 2.2 to 2.8 for the location of the parts. Table 9.2 – 1-5 HP Drive Replacement Parts Quantity per Horsepower Description*...

  • Page 93: Table 9.4 - 15-25 Hp Drive Replacement Parts

    Table 9.4 – 15-25 HP Drive Replacement Parts Quantity per Horsepower Description* Part Number 25** NEMA 1 Fan Assembly 615161–V NEMA 4X/12 Fan Assembly 615161–S NEMA 1 Cover 805547–1S NEMA 12 Cover/Gasket 805547–2S Membrane Switch Keypad/Top 805548–1R Bracket Regulator PCB 0–56921–6xx IGBT Module 602909–813AW...

  • Page 94: Table 9.5 - 25-60 Hp Drive Replacement Parts

    Internal Fan 615196–2R Assembly * Components are identified in figure 2.5. ** M/N 25V4160 and 25V4260. *** M/N 60G4160 and 60G4260. **** Replace the Gate Driver Board when the IGBT modules are replaced. 9-14 GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 95: Table 9.6 - 60-100 Hp Drive Replacement Parts

    Table 9.6 – 60-100 HP Drive Replacement Parts Description* Part Number Quantity Regulator PCB 413338–6BU Power Module Interface PCB 413338–5AW Power Module Interface PCB Fuses 413338–5AB Keypad 413338–5AX Gate Driver PCB 413338–5D Bus Clamp PCB (right) 413338–5E Bus Clamp PCB (left) 413338–5F Intelligent Power Module (IPM) PCB 413338–5J...

  • Page 96: Table 9.7 - 100-150 Hp Drive Replacement Parts

    * Components of the 100-150 HP drives (M/N 125R4160) are identified in figure 2.7. **It is recommended that the Gate Driver PCB and the Bus Clamp PCBs be replaced at the same time as the IPM PCB. 9-16 GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 97: Table 9.8 - 200-400 Hp Drive Replacement Parts

    Table 9.8 – 200-400 HP Drive Replacement Parts Description* Part Number Quantity Phase Module Assembly 807300–124R 3*** Phase Module Assembly 807300–158R SCR Module Assembly 807300–200R Blower Motor 616300–100R Blower Starter Capacitor 69932–24QK Fault Thermostat 66012–16B Gate Driver PCB 0–56956 DC Bus Capacitor 600442–34SU 10/18**** SCR Diode...
  • Page 98 9-18 GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 99: Appendix A Technical Specifications

    PPENDIX Technical Specifications Table A.1 – Service Conditions AC Line Distribution System Capacity 1000KVA, three-phase with 30,000 amps symmetrical fault (maximum) for 460 VAC Units current capacity with a line impedance of less than 5%. (85,000 amps fault current capacity with optional AC line reactors. See table 5.1.) Control Method All-digital vector, sinusoidal pulse-width-modulated (PWM)
  • Page 100 Resistor Braking Kits, such as the M/N 2DB4010 series, that require a gate turn-on signal from the drive. Table A.5 – Terminal Strip RS-232 Specifications Signal Type Terminal(s) Specification RS 232 Communications XMIT RECV COMMON GV3000/SE AC Drive Hardware Reference, Version 6.06...
  • Page 101 Table A.6 – Encoder Feedback Device Specifications (FVC Regulation Only) Specification Rating Motor Poles 2, 4, 6, or 8 poles Overcurrent IET 200% load (based on drive nameplate rating) Overload Current Rating 150% for 1 minute (based on drive nameplate rating) Speed Control Range 1:600 with 1024 PPR Speed Control Response...
  • Page 102 GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 103: Appendix B Compliance With Machinery Safety Standard En 60204-1:1992

    PPENDIX Compliance with Machinery Safety Standard EN 60204-1:1992 The GV3000/SE drive complies with the following sections of machinery safety standard EN 60204-1:1992. EN60204-1 Section Title Protection against electrical shock 6.2.1 Protection by enclosure 6.2.3 Protection against residual voltages 6.3.1 Protection by automatic disconnect of supply...
  • Page 104 Identification of the protective conductor Warning signs and item identification 18.2 Warning signs 18.4 Marking of control equipment Technical documentation 19.1 General Copies of this standard can be purchased from the American National Standards Institute at www.ansi.org. GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 105: Appendix C Compliance With Electromagnetic Compatibility Standards

    • instructions on how the drive must be wired. The GV3000/SE drives listed on the Declaration of Conformity (DOC) and in table C.1 have been tested and are in compliance with the following standards when installed with the appropriate AC Mains Filter: •...
  • Page 106 C.2 Compliance Requirements In order for the GV3000/SE drive to conform to the standards listed in section C.1, the drive must: • be specified by model number on the DOC. • have a CE mark. This mark is found on the drive’s certification label.
  • Page 107 2DF4286 75T41xx 125R41xx 2DF4125** 200V41xx 250V41xx 300V41xx 350V41xx 400V41xx * Filter is internally mounted in the GV3000/SE drive at the factory. ** Does not comply with standard EN50081-1 (1992) *** Contact Reliance Electric for assistance. Compliance with Electromagnetic Compatibility Standards...
  • Page 108 Use the following guidelines to mount the GV3000SE drive to the AC Mains Filter and then mount the drive/filter assembly to a panel: • Attach the GV3000/SE drive to the AC Mains Filter. See figure C.1. No other type of mounting is permitted. The required mounting hardware is supplied with the filter. •...
  • Page 109 C.3.2 Installing AC Mains Filters in GV3000/SE Drives M/N 50T41xx and 75T41xx In GV3000/SE drives M/N 50T41xx and 75T41xx, the AC Mains Filters are installed within the GV3000/SE chassis at the factory. No additional filter installation is required. Continue with section C.4.
  • Page 110 4.3" 5.1mm GV3000/SE 0.2" 65mm 30mm 2.5" 1.1" 30mm 320mm 1.1" 12.5" 160mm 6.2" 40mm 80mm 80mm 80mm 1.5" 3.1" 3.1" 3.1" 320mm 12.5" Figure C.2 – M/N 2DF4125 AC Mains Filter Dimensions GV3000/SE AC Drive Hardware Reference, Version 6.06...
  • Page 111 C.4 Wiring Practices This section describes how the GV3000/SE drive must be wired to conform to the standards listed in section C.1. Figures C.3 and C.4 show GV3000/SE wiring configuration examples. Mains GV3000/SE Filter U,V,W AC line input Screened 4-wire motor cable...
  • Page 112 Cabinet-protection ground bus bar Cable bracket Screen Screened 4-wire motor cable Screened signal conductor cable (feedback, reference) U,V,W EMC-tested armored cable gland at terminal box MOTOR Figure C.4 – Cabinet-Mounted GV3000/SE Wiring Example GV3000/SE AC Drive Hardware Reference, Version 6.06...
  • Page 113 C.4.1 Connecting the AC Mains Filter Output to the GV3000/SE Drive Input The following sections describe how to wire the AC Mains Filters to the GV3000/SE drives. C.4.1.1 Connecting AC Mains Filters M/N 2DF4283, 2DF4284, 2DF4285, and 2DF4286 The power leads that connect the output terminals of the AC Mains Filter to the drive’s AC input terminals are included with the filter.
  • Page 114 FILTER'S AC INPUT POWER MOTOR Figure C.6 – Typical Three-Phase Connections for Built-in AC Mains Filters in GV3000/SE Drives M/N 50T41xx and 75T41xx C.4.1.3 Connecting AC Mains Filter M/N 2DF4125 The power leads that connect the output terminals of the AC Mains Filter to the drive’s AC input terminals are user-supplied.
  • Page 115 AC input power leads to the terminals at the top of the filter. See figure C.1. The AC input power leads should have lugs attached. The filter-GV3000/SE cabinet has a conduit opening to secure the AC input power conduit.
  • Page 116 15 mm length: one of the colors should cover at least 30% and no more than 70% of the surface, with the other color covering the remainder of the surface. C-12 GV3000/SE AC Drive Hardware Reference, Version 6.06...
  • Page 117 Screen pigtails are not permitted. C.4.7 Connecting to the AutoMax Network GV3000/SE drive connections to an AutoMax network require the use of coaxial cable as described in instruction manuals J2-3001 and D2-3308. The coaxial cable must be run in continuous, rigid, conductive conduit.
  • Page 118 C.4.8 Encoder Cabling Use only the Reliance Electric encoder cables listed in table C.3. Table C.3 – Encoder Cabling Cable Type Cable Length Cable Model Number MS connector on encoder end 25’ 2TC4025/2TC3025 MS connector on encoder end 75’ 2TC4075/2TC3075 Bare wire on both ends 100’...

  • Page 119: Appendix D 200-400 Hp Gv3000/Se System Wiring Diagrams

    PPENDIX 200-400 HP GV3000/SE System Wiring Diagrams 200-400 HP GV3000/SE System Wiring Diagrams...
  • Page 120 GV3000/SE AC Drive Hardware Reference, Version 6.06...

  • Page 121: Index

    NDEX Numerics 115 VAC Interface Option Board, 2-21 Capacitor board location, 2-4, 2-5, 2-6 part number, 9-12, 9-13 Capacitors, DC bus, 9-1 to 9-7 Carrier frequency, 2-11, A-1 AC disconnect (optional), location of, 2-10 Closed-loop control, see Vector Regulation AC input Conduit plugs, replacing, 4-2 diodes, checking, 9-9 to 9-10 Connector...
  • Page 122 9-15, 9-16, 9-17 CS3000 RS-232 Computer Cable, 2-21 Grounding, 3-5 to 3-6, 4-2, 5-3, 5-4 DeviceNet Network Option Board, 2-21 Fan Kit for Line Regeneration Modules, 2-20 Interbus-S Network Option Board, 2-20 Index-2 GV3000/SE AC Drive Hardware Reference, Version 6.06...
  • Page 123 Line Regeneration Modules, 2-20 Motor Encoder Cable, 2-20 Operator Interface Module, 2-21 OIM, see Operator Interface Module Profibus Interface board, 2-21 Open-loop control, see Volts/hertz regulation Remote Meter Interface board, 2-20 Operator Interface Module (OIM), 2-21 Snubber Resistor Braking, 2-20 Operator Interface Module connector, 2-19 Snubber Transistor Braking, 2-20 Option board connector, 2-19...
  • Page 124 A-2 wire sizes, 3-5 to 3-7 Specifications, technical, A-1 to A-3 Speed, setting maximum, 7-7 Start (digital input 1), 2-18, 7-2, 7-4, 7-5, 7-16 Start enable see Function Loss Index-4 GV3000/SE AC Drive Hardware Reference, Version 6.06...
  • Page 125 After you have completed this form, please return it to: Reliance Electric Technical Documentation 24800 Tungsten Road Cleveland, Ohio 44117 Fax: 216.266.7785 Publication Name: GV3000/SE AC Drive Hardware Reference, Version 6.06 Publication Number: Publication Date: D2-3360-5 December 2000 Comments: Your Name:...
  • Page 128  2000 Rockwell International Corporation. All rights reserved. Printed in USA. Publication D2-3360-5 - December 2000...

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